My little engine (continued)

[GarryCParticipant @garryc]

Thanks Jason – yes of course I should have remembered from the Crankshaft Bearings earlier, giving the mating surfaces a rub is a good and easy way to close them up a fraction at a time..

I'll have a look and see if I do have anything the right size, bet I'm not that lucky though. I have found the gauges to be quite repeatable when I have used them in the past – I'll go even slower than usual doing it (if that's possible!)..

I'll remember the soluble oil tip and get some in when I have to get some more cutting oil..

Cheers

Garry

Edited By Gary on 05/06/2015 16:53:46

[GarryCParticipant @garryc]

Bear with me with this little sequence probably won't be of much interest to others I expect but will be to me when I look back in the future..

Thanks again for the tip to use something as a Plug gauge (Jason and Steve) – It was very good to be able to check the accuracy of what I was doing along the way.

Not saying things are exact of course but close I hope – all these readings in the photo were checked by re-entering the gauge several times but there was occasionally some discrepancies – small ones. The bore gauge set was only a very cheap one but they seem to work well if you don't mind double checking them when using.

Result was about 1 thou oversize – I actually had the bore at the exact same reading on the mic as the crankpin but then deliberately went oversize just in case – bit more than I wanted to perhaps – only passed the boring bar through again at the same setting and it took another thou – still hoping it should be ok and easy to adjust now when they are fitted.

Next time around having an accurate plug gauge made from the start would be quicker and better I think..

Cheers again all for the advice – very enjoyable little session doing it!

The Crankpin Size.

Drill bit shank to check the accuracy using the bore gauge along the way.

Using the Bore Gauge.

The Bore gauge showing the bore to be the same as the test drill bit shank.

The Drill Bit just about enters the bore so hopefully things are not too far out, it wouldn't go in any further than this..

The Final Bore Reading – just over the crankpin size so can adjust the bearing mating surfaces with some wet and dry to get a good fit..

Regards

Garry

Edited By Gary on 06/06/2015 12:25:00

[mechman48Participant @mechman48]

Garry, thanks for the app link / info..

George

[GarryCParticipant @garryc]

Ok, thanks George..

A couple of photo's of this mornings progress..

Luck was with me again today when I didn't have the bearing securely in the chuck when doing the register for the con rod foot, was holding too lightly and trying not to mark it – it moved and I had to use the mill as it was difficult to centre back on the lathe. Could have been a lot worse – the mill did a great job though of centring with the edge finder and the result was a lucky and very nice fit. Pure luck the register on the foot was within a thou of 8mm and so I used an 8mm slot drill – was going to bore on the lathe, could have been a bit trickier if I'd had to put it back on the lathe to do that.. I must be due a set back soon, I've got away with it twice now just lately…

Both diameters now turned.

The register although looking a bit ugly is a really nice fit, no movement and its where it should be – I had to open out the hole a tiny bit on the end with a drill bit to let in my bad shoulder on the con rod register – didn't have a decent tool to get that clean when I did it is my excuse..

You can see in the bottom of the hole where the lathe chuck let go.. My fault of course.

Made sure the foot was symmetrical about the centre line.

Not too bad so far – the chuck marks on the ends will disappear when it goes back on the lathe.

Next is to drill the for the fixing bolts – quite deep holes these all the way through, have to see how that goes and keep an eye on the bits not getting too hot as Jason mentioned..

Cheers

Garry

Edited By Gary on 07/06/2015 16:12:03

Edited By Gary on 07/06/2015 16:25:00

Edited By Gary on 07/06/2015 16:30:40

[BERT ASHTONParticipant @bertashton57372]

You are making excellent progress Garry, keep up the good work and your great photographs.

Bert Ashton.

[GarryCParticipant @garryc]

Thanks Bert – hope you're making progress in finding your Old Engine.

Cheers

Garry

Edited By Gary on 07/06/2015 16:28:28

[Gas_mantle.Participant @gas_mantle]

Looks like you made that foot out of a solid gold block

[GarryCParticipant @garryc]

Now there's a thought Peter, I wonder what gold turns like!

[Anonymous]

Posted by Gary on 07/06/2015 17:24:01:

Now there's a thought Peter, I wonder what gold turns like!

Well pure gold is pretty malleable, so I suspect it would be 'orrible to machine, like copper, only worse.

Andrew

[GarryCParticipant @garryc]

Hi Andrew

Wouldn't mind giving it a try though..!

I wasn't too successful today and only drilled a couple of holes for the bearing bolts – found the material difficult with lots of heat being generated very quickly (often followed by some 'binding' type noises) and the holes were not too accurate when I had finished… I think I can understand the soluble oil comments after today and even managed to burn my finger on one of the bits! It'll be handy to have some cooling oil. Found it all an Interesting experience though! I thought the holes were maybe a bit deep for the slot drills so I was only using drill bits.

I was going to countersink but I think it would have been ugly with the holes not being accurate.. The surfaces are all flat so hopefully it will be ok.

I didn't spot through the holes to the foot, it would have been difficult to hold for that I thought – but the 1 inch hole centres matched up perfectly which was great.

I'll have to be careful to get things parallel when I do the little end. Next though is to put the assembled con rod and bearing back on the lathe to radius the bearing sides with the foot..

Cheers

Garry

[GarryCParticipant @garryc]

Just a quick session today to radius the bearing sides with the foot..

a little video of one of the passes – 15 thou..

The bearings sides looking a bit better..

and after it was finished..

Next on to squaring up the little end about the centre line and parallel with the assembled bearing..

Regards

Garry

Edited By Gary on 09/06/2015 13:10:44

Edited By Gary on 09/06/2015 13:13:17

[JasonBModerator @jasonb]

Are you going to turn the waist on the bronze bearing which is a typical detail?

[GarryCParticipant @garryc]

Hi Jason

I was wondering about that – but I can't see quite how to go about it. I see from photo's on the internet that not everyone has but I'd have a go I f I could!

Its the 'outward curving' shoulder that I can't see how to do..

edit –

ah I've just been looking again and I think I see that its another round nosed tool job – I still haven't found my indexable one and only have the HSS tool steel that I rounded myself – its not very good so maybe I should think twice! I'll have to get another decent round tool if i can't come across mine as they seem to be really useful..

 

Cheers

Garry

Edited By Gary on 09/06/2015 13:18:26

Edited By Gary on 09/06/2015 13:31:55

[JasonBModerator @jasonb]

Just needs a smallish round nose tool say bit of 4mm HSS ground with a 2mm radius or as I see you have some of the brazed tip tools the ones with the rounded end are quite useful, a left or right hand one set so the end is square to the job and just move back and forth as you gently feed in.

[GarryCParticipant @garryc]

That does look a lot better Jason, thanks for the photo – and of course its as per the drawing. I've got some very small bits of tool steel I could put a round end on or maybe one of my new tools. I'll see if I can have a go tomorrow..

[JasonBModerator @jasonb]

Its always the way, you buy a set and it has bits you won't use but never contains the ones you want

And some HSS ones 10, 6 and 4mm

[GarryCParticipant @garryc]

Jason, thanks its so useful to see that – I've recently been thinking to order some HSS blanks to have a go with..

Not much idea of tool shapes yet, Il'l keep those photos to copy from..

My holes yesterday were out most likely because I'm not punching accurately, there're all blunt and I can't feel the lines – I've been struggling with them for a while. They cost next to nothing and I keep forgetting to get some more when I'm ordering – then this morning all of 5 seconds each on the grinder and I had them back to sharper than new, I had just kind of assumed it would be difficult to do and the hardened steel would make it worse… It's an age thing I think! Turns out It was just so impossibly quick and easy, I must get more into it, tool grinding seems to be an essential skill I should have got comfortable with ages ago.. oops I'm waffling on again..

Ta very much

Garry

[JasonBModerator @jasonb]

Good to hear you had a go, if they were blunt you have nothing to loose by trying. Just watch them the first time you use them on a critical size incase they cut a little bit over. Even if they do they can be kept for when you are drilling out in stages and keep the new ones for the final sizing cut that way the new ones won't wear too fast.

[alan-lloydParticipant @alan-lloyd]

The carrier is on the wrong side of the drive pin in one of your previous posts, you are pulling the work piece instead of pushing it,

[GarryCParticipant @garryc]

Ok Jason, that makes good sense, seems a bit crazy now that I've been managing with only one or two lathe tools since I started..

Hi Alan

Thanks it may have been the one some others have noticed as well, I've been a bit more careful since!

Nice looking bike..

Cheers

Garry

[GarryCParticipant @garryc]

Just been squaring up the Little End ready for marking out today. Its taken a bit of time making sure each of the 4 faces are to size and parallel in both planes to the crankshaft.

Also sent for some 3/8" x 4" square HSS Lathe Tool blanks to have a go at making some tools – after rethinking probably makes sense to have some practice and see how things go before using them live as it were – so as I don't have anything round nosed and suitable now I'll probably leave the waist around the bearing this time..

Checking to make sure all faces were right for machining. Measurements all taken from the centre line..

Cheers

Garry

[James BParticipant @jamesb]

Hi Garry,

Have been following your build diary with interest – great job!

Have a look at the 7th post down the page on the link below – uses an old centre drill to make a profile tool. I have saved this for future use, thought it was an excellent way of making a radius tool…

Profile Tool

James

[Nick_GParticipant @nick_g]

Posted by James Burden on 10/06/2015 15:37:54:

Profile Tool

James

Aaaaahhhhhhhhhhhh.

If like me someone is a dunce at tool grinding let alone one symmetrical on both sides that's a fab idea.

Nick

[GarryCParticipant @garryc]

Hi James

Thanks, agree with Nick that is a very nice idea!

I can't see from the text in the link and was wondering if it was welded or soldered on the end? I tried to cut tool steel once with a hacksaw – I wonder if the excess was ground away and if some 'relief angle' is needed on the end?

Very interesting. Looks such a simple thing yet I can't answer any of those basic questions..!

Cheers.

Garry

[Gas_mantle.Participant @gas_mantle]

Hi Garry,

Like others have said I also enjoy following this thread and think you are doing a great job.

What does amaze me is how clean your machinery is, I've yet to see any swarf in the photos.

If I didn't know better I'd swear you bought a ready made engine and just photograph a different part in the chuck everyday and tell us you made it

Peter.

[Author]

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